Feeder for producing stock material



3, 1965 M. M. GRACER 3,197,850

FEEDER FOR PRODUCING STOCK MATERIAL Original Filed July 9. 1959 4Sheets-Sheet l INVENTOR ATTORNEY a- 3, 1965 M. M. GRACER 3,197,850

FEEDER FOR PRODUCING STOCK MATERIAL Original Filed July 9, 1959 4Sheets-Sheet 2 INVENTOR /K4ZATTORNEY Aug. 3, 1965 M. M. GRACER FEEDERFOR PRODUCING STOCK MATERIAL Original Filed July 9, 1959 4 Sheets-Sheet3 Q EE NE mm %6TTORNEY Aug. 3, 1965 M. M. GRACER 3,197,850

FEEDER FOR PRODUCING STOCK MATERIAL Original Filed July 9, 1959 4Sheets-Sheet 4 INVENTOR M %v h ATTORNEY United States Patent 3,197,859FEEDER FOR PRODUUING STUCK MATEREAL Martin M. Gracer, 71 Laurel Drive,

' Massapequa Park, N.Y.

Original application July 9, 1959, Ser. No. 825,954, new Patent No.3,129,22ti, dated Apr. 7, 1964. Divided and this application Mar. 8,1962, Ser. No. 178,487

Claims. (Ci. 29-243.5)

This invention relates to flexible connector stock and machine andmethod for making the same.

This application is a division of my application Serial No. 825,954,filed July 9, 1959, which issued as Patent No. 3,129,220 on April7,-1964 and entitled Flexible Duct Connector Method of Making the Sameand Resulting Product, which is a continuation-in-part of my applicationSerial No. 470,203, filed by me on November 22, 1954, now abandoned.

In my application aforesaid, I have provided a flexible duct connectorstock for joining the ends of ducts to provide a flexible seal asbetween a blower or furnace and the duct leading therefrom in which twoelongated lengths of sheet metal strips and a length of duct sealingfabric are joined in the composite so that each of said metal strips isjoined to the opposite side edges of the fabric. Specifically, in saidapplication, the juncture between the fabric and the metal is formed bydouble folds, bending the metal into a flat tubular convolute of atleast about one and one half turns, and double clinched in thiscondition by flattening the same during folding. Such composite of twostrips of metal and a single web between them is then formed into a ductoutline, either round or rectangular, to extend the opposite strips forjuncture with permanent duct installations, to align the duct and ablower or furnace to accommodate for dimensional aberrations, to absorbobjectional vibrationswhich might be transmitted through the length ofthe ducts. Stock for making such connectors is supplied to the market inextended lengths or coils of from fifty to one hundred feet, from whichsections are cut oif in the field for use. These coils are, in ameasure, cumbersome to handle in that if coiled into a roll of too smalla radius, the product will assume a permanent set when bent above theelastic limit of the composite and there then is involved the work ofmalleting, to take out the creases or waviness.

While other transverse bending stresses to which the composite abovedescribed is subjected, such as in the formation of duct outlines byinner and outer folds, do not relax the clinching between the metal andfabric by reason of the double fold in accordance with my priorapplication, a degree of inflexibility is experienced which involvesunnecessary, highlabor costs for handling.

I have found that in a connector in accordance with my presentinvention, I may beneficially retain a joint between the strips of metaland the composite edges of the duct sealing fabric employing a doublefold in accordance with my prior invention whereby, in the extendedcondition of the metal strips in respect to the common fabric, abrasionof the fabric by the metal is avoided, securing other economies inpackage size of the stock and labor handling costs to form duct outlinestransversely bent either at sharp angles or in gradual curves, employingheavy gauge sheet metal, by forming weakened areas along the folds inthe composite where they are formed to clinch the metal to the fabric.Specifically, by providing transverse cutouts or scores, so that inretaining the benefits of a tubular convolute in clinching the metal tothe fabric on its opposite edges, a more intimate engagement may beefiected between metal and fabric by scoring the sheet which forms aportion of the convoluted Patented Aug. 3, 1965 edge, thereby securing,in the formation of a coil of the stock, a more compact and economicalpackage.

Still more particularly, it is an object of my invention to provide aflexible connector stock having uniformly shaped metal strips connectedto opposite edges of a length of ductsealing fabric employing, at themetal strip side edges, a double fold, resulting in a tubular convoluteof more than one turn, in clinched engagement with the fabric and whichmay be handled in overlapped condition of the three components of metaland fabric economically and efiiciently, and be readily severed whenrequired, with the same case as a thinner stock.

Still more particularly, it is an object of my invention to provide alength of flexible connector stock composed of duct sealing fabricjoined on its opposite edges by metal strips having double folds toclinch the fabric and metal to each other, in which a Warped conditionis minimized, if not entirely, eliminated, in which economy in space iseffected, package sizes of long lengths are reduced, strong grip betweenfabric and metal is assured and accuracy in handling is enhanced.

Still more particularly, it is an object of this invention to provide ahighly efficient method and apparatus for forming connector stock, whileeffecting economies in production, storage and power forces in combiningthe layers of metal and fabric into clinching engagement to produce adouble edge fold of metal to opposite sides of a duct sealing stock offabric.

To attain these objects and such further objects as may appear herein orbe hereinafter pointed out, I make reference to the accompanyingdrawing, forming a part hereof, in which: I

FIGURE 1 is a fragmentary perspective view showing the componentsentering into the stock in accordance with my invention;

, FIGURE 2 is a sectional view showing an initial con dition of junctureof the components shown in FIG- URE 1;

FIGURE 3 is a sectional View showing the final condition of fold of thecomponents shown in FIGURE 1;

FIGURE 4 is a plan view in the direction of the arrows 4-4 of FIGURE .3,with the parts overlapped ready for packaging;

FIGURE 5 is a fragmentary section taken on the lines 5-5 of FIGURE 4;

FIGURE 5:: shows a coil of the product;

FIGURE 6 is a perspective view of the ultimate prodnot, ready forbending transversely;

FIGURE 7 is a section taken on the lines 77 of FIG- URE 6;

, FIGURE 8 is a perspective view of an oblong form of duct made from theconnector in accordance with my invention, with an inside fold offabric;

FIGURE 9 illustrates a cylindrical form of duct in accordance with myinvention, with an outside foldof fabric; j

FIGURE 10 is a longitudinal diagrammatic side elevation of ameans offorming the product in accordance with my invention;

FIGURE 10a is a fragmentary plan view of the positions of the stripswhen punched;

FIGURE 11 is a magnified fragmentary plan view of the aligning andmetering components;

FIGURE 12 is a section taken on the lines 12-12 of FIGURE 10;

FIGURES 13 to 21 are side elevations, with work in section, showing theforming rolls in progressive steps in making the double edge fold of thecomposite in accordance with my invention.

Making reference to the drawing, a flexible connector stock inaccordance with my invention is pro- V 3 vided from a length of ductsealing fabric 111 and strips of sheet metal 11 and 12, different widthsof such strips being employed, if desired.

The section may constitute duck impregnated to render the sameimpermeable to air or may be sections of woven asbestos fabric, alsosuitably treated to make the same relatively impermeable to the flow ofare each at least more than one half of the width of the fabric '10, andpreferably one strip is of greater width than the other. For purposes ofillustration, the strips may be four inches and five inches,respectively, and each is formed adjacent the side edges 13 and 14 withslotted cutout portions 15 of oblong outline, thelength of which oblongis at least twice the overhang 16 between the outeredge walls 17 and 18and the side edges 13 and 14, respectively. The width of the oblong ispreferably, though not necessarily, large enough to provide clearancefor the blade of a metal snipper. Where the slots 15 are made by apunching die, which is preferred, the burrs 15a are left to extend inthe same facial direction for each strip 11 and 12, to provide a moreintimate fabric engagement when pressed into engagement {with the same.

With lengths of strips 11), 11 and 12, so provided, the leading edges19, 20 and 21 of the three comunscored coil of similar length and gauge,in accordance with my prior application.

The space saving factor not only effects economies in storage andtransportation but facilitates ease of handling due to the reduced bulkso that one individual may handle a carton as compared with thenecessity for handling of the larger size carton by two workmen. Coilingto the smaller dimension is possible without effecting waviness ordistortion. A cut off length will quickly lie flat and may be readilyworked and be bent to sharp corners on a bending brake, withoutrupturing the fabric, andin fact permitting the use of bending brakes tomake corners of an angularity i which normally would weaken the fabric.

p as described in my prior application, in coils.

When bent along the cross notches, the composite will furnish sharpcornered duct outlines without requiring an undue amount of malleting orbending dies to square up a corner. Forming inside folds (see FIGURE 8)or outside'folds (see FIGURE 9) of the fabric in the formation of theduct of oblong outline O, or cylindrical outline C collars does notrelax the clinched condition of the folds of metal and fabric indifferential contraction due to the thickness of layers. Where the burrs15a are formed by punching dies in making the notches 15, finishingoperations to remove the burrs .are unnecessary as the burrs enhance thegrip between the fabric and condensing the enfolded fabric in clinchingthe folds.

The product aforementioned may be made in limited lengths or extendedlengths and stacked flat, one layer superimposed on another, or made incontinuous lengths of from fifty to one hundred feet for handling, Theemployment of scored or notched blanks for making the composite hascertain additional advantages and may be conveniently produced byprocedure and ap ponents are joined with the strips 11 and 12,overlapped attheir edges 22, 23 for a distance to space the same so thatthe edges 17 and 18 are aligned with the side edges 24, 25 of'the fabric10. In this position, the edges 13 and 14 are given a first fold 26, 27,as shown in FIGURE 2, and then a second fold 28, 29, to form a tubularconvolute of more than one turn,

in the illustration providing a turn and a half of three layers of sheetmetal and fabric except at the notched out portions 15..

Flattening the convolute to press the layers into intimate engagement atthe folds will direct the burrs 15a previously described into greaterfrictional face engagement with the fabric. The width of the scoringwith relation to the folded-in portion or overhang 16 extendsdiametrically across the convolute, to expose only two layers of sheetmetal between the remnants ofmetal effected by the scoring 15. Thespacing 31 defined by the scores 15 is of a nature to permit entry ofthe blade of hand snips to cut off or fashion the composite in thefurther procedure of converting a length of stock into a duct, andthereby facilitate this 7 tiresome operation.

' to concentrate the punch power.

A long, loose hanging flight 33 is'provided beyond the punching zonewhich permits the strips 11 and 12 to be crossed over each other andreversed two ways from side by side position to another so that thescores or cutouts 15 are positioned remote from each other instead ofbeing adjacent to each other as at the punching operation, and toposition the lower faces so that they are upwardly directed. The burrsformed incident to the punching operation, which were downwardlydisposed at the punch zone, thus are also upwardly faced. The strips arethen overlapped, as shown in FIGURE 1, with relation to a width of dustsealing fabric and the leading edges fixedly secured together, as byriveting or spot welding, so as to enter the hold down rollers 34 in apredetermined length of 24 to 26 gauge metal, in accordance with myinvention, may be packaged in a twenty-four inch square box, five to sixinches deep, as compared with the necessity for using a thirty-six inchbox for an spaced apart, overlapped position, where the mated strips 11and 12 are guided upon the platen 35, having side channel guides 36,36a. The hold down rollers 34 optionally may, if desired, haveinterfitting sprockets for engaging the scores or cutouts 15, tocoordinate movement of the independent strips in unison without anyrelative differential movement. Suitable adjustablemeans (not shown) forurging the rollers into pressure engagement in accordance with thethickness of the composite of metal may be employed, as will be readilyunderstood, and this arrangement is effected for all of the journalboxes for the shafts of all of the guides or forming rolls in accordancewith sound practice.

The side 13 of the strip 11 is thereby guided in abutting relation tothe upstanding channel flange 36a and the side edge 14 of the strip 12is abutted against the upstanding channel flange .36. Thereupon thestrip enters be- 5. tween opposed pairs of aligning mated rollers 37,37a and 38, 38a, which grip the strips 11 and 12 through cutouts 39 inthe platen 35, as shown in FIGURE 12.

The aligning mating rolls 37 and 38, and 37a and 38a,

are of the same diameter and are preferably, although not necessarily,held on the common shafts. The rolls are free rolling on their commonshafts 40 and 41. Ball bearing rollers (not shown) with inner and outerraces are provided, the rolls rotating on the inner races. The shaftsare fixedly mounted and do not rotate. The interengaging mating rolls 37and 38, 37a and 38a are designed to maintain the edges 13 and 14 indiverging relation and in pressure contact with the upstanding channelguides 36a and 36, respectively, beneath the hold down brackets 36b.This is effected by providing toe-in or leading edge camber to the rollsand by bending the shafts 40 and 41 a small angle, say 2 /2. Thecontinuing outward pressure against the accurately parallel, upstandingchannel of guides 36a and 36 thereby avoids any inaccuracy or variancein width of the strips 11 and 12, which overlap sufficiently (the amountof overlap short of reaching the opposite edge being immaterial) and atthe same time, by use of the series of forming rolls to be described,avoiding any guides whatever at an intermediate' point, assure anaccurate spaced relationship between the edges 13 and 14 of the stripsin the further processing of the strips. The strips 11 and 12 thenproceed to engagement between pairs of metering mating rolls 42, 42abelow and above the platen or bed 35. The metering rolls 42 and 42a arecylindrical and are truly square with relation to the axial line ofendwisely journalled upper and lower connecting shafts 43, to which themetering rolls 42 and 42a are keyed, to rotate the upper face rolls 42,42a in unison and the lower face rolls 42 and 42a in unison. However,the shaft coupled rolls 42, 42a may be of differential diameter,depending upon whether the ultimate product is being packaged flat or incoils. Where the product is to be packaged in coils, I have devisedmeans for assuring a length of the metal strips and fabric to beunwa'rped, when coiled and then uncoiled, by a reduc: tion in theperipheral feed of the metering rolls42a. This is accomplished byturning down the metering rolls 42a so that they have a peripherallength of one and one half inches less per one hundred feet than themetering rolls 42, with a 24 gauge stock of sheeting, as an example.Variations in coil characteristics, i.e., number of convolutions andlength of stock with different thickness of metal and differentthickness of fabric, will require variations in the differential betweenthe pairs of metering rolls and machine design to meet the changedconditions, will accordingly now be apparent.

The strips then pass between hold down plates 44, after which they arefed below the guide roll 45, whereby they meet the flight of ductsealing web of fabric 19 fed thereto from the roller R over the guiderolls 46 to tauten the same.

The web of fabric is centered with regard to the overlapping strips 11and 12 so that the overhang 16, previously described, projects to eachside edge of the fabric or selvage edge of the fabric, where a selvagededge fabric is employed. For a five inch width fabric, the plates arepositioned so that the edges 13 and 14 are spaced apart so that eachgives an overhang of approximately five sixteenths of an inch, and pressthe fabric completely to cover the scores or cutout and into engagementwith the upstanding burrs 15a, and to compact the fabric for secureengagement. A three layered flat composite is then fed into thespaced-apart parallel series of mated upper and lower forming rolls,nine double groups being shown, where the double fold edges areimpressed on the composite to form a flattened convolute of one and onehalf turns, pairs of upper and lower forming rolls 47, 47 and 47a, 47aimpressing upon the edges 13 and 14, respectively, a 45 bend adjacentthe weakened line of fold of the innermost wall of the cutouts 15, toengulf the edges 24 and of the fabric 10. The provision of common,integrated shafts for the laterally spaced rolls and coupling for themated forming rolls will be understood as desirable to assureuniformity, and therefore have not been illustrated.

The web then passes through pairs of mated upper and lower forming rolls48, 48 and 48a, 48a, shown in FIGURE 14, where the edges 13 and 14 aregiven a further bend, to bring the same to 90. Pairs of upper and lowermated forming rolls 49, 49 and 49a, 49a bend the overhand to 135, asshown in FIGURE 15. Pairs of upper and lower mated fold rolls 50, 50 and50a, 50a, as shown in FIGURE 16, form the overhang edge into the firstfold 26, 27, and clinch the metal into engagement with the fabric.Thereupon the composite is fed to pairs of upper and lower mated'rolls51, 51, 51a, 51a, in which the first fold is bent 30, as shown in FIG-URE l7. Thereupon'the composite moves to pairs of upper and lower matedrolls 52, 52, 52a, 52a, where the first fold is given a further bend of30, as shown in FIG- URE 18. Thereupon, the composite moves to pairs ofupper and lower mated rolls 53, 53, 53a, 53a, where the first fold isgiven an additional bend to 90, as shown in FIGURE 19. Thereupon thecomposite moves to pairs of upper and lower mated rolls 54, 54, 54a,54a, where the first fold is bent to an angle of 135, FIGURE 20. Thenthe composite moves to pairs of upper and lower mated rolls 55, 55, 55a,55a, where the first fold is bent 180,

FIGURE 21 to flatten and clinch the edges to the final convolute.

Each of the cooperating upper and lower rolls 47 to 55 which form theedge fold 29, maintains a differential peripheral length as comparedwith the series of rolls 47a to 55:1, which form the double fold 2%, tohave the fold 29 of lesser peripheral length than the edge fold 28,thereby assuring a linear arrangement of the composite web at its sideedges without any warping or camber or evidencing objectionable bucklingwhen the finished product is coiled and uncoiled. As the length is fedinto mating end guide rolls 56, 57 at the zone 58, periodic shearing maybe effected by the shears 59 as the length is fed to a take-up creelwhere a core may be located, or a take-up linear chain carrier 60. Wherea take-up carrier is employed, the composite may be stored flat inlengths of one hundred feet to be used from this source, or then woundinto coils about a core which will provide an outer diameter of coil oftwenty-four inches for such length, thereby permitting storage in a twofoot square carton as compared with a three foot square carton forsimilar gauge metal and length of strip in previous packages. Such closecoiling is made possible from flat stock or creeled stock at the station60 without creating any permanent set in the composite when it is readyfor use in the field, and has the advantages previously described as toflexibility, trueness of alignment and freedom from waviness.

The notched portions or scores provide weakened lines of fold,minimizing the stresses for making the folds and facilitating a pacingof the strips 11 and 12 to prevent differential stressing or crowding ofthe length of the composite occasioned by the overlapping and themulti-layers which have been convoluted into the double folds. Benefitsinure from the simultaneous folding operating of three composites inavoiding objectionable differential length or camber or warping as wellas in permitting a creeling at the zone 60, with less tension componentsin making a coil of relatively small diameter. Yieldability by reason ofthe slotted or scored portions 15 permits tight coil creeling directlyfrom the forming rolls or from stored continuous straight lengths of thecomposite, with the assurance that when the packaged coil is unrolled,lengths may be severed without waste.

I have not specifically shown the coupling of the shafts of the variousmated feeding and forming rolls which have the ends of their supportingdrive shafts extended and provided with suitable drive gears which arecoupled to suitable 'driving means to assure powerized rotation incoordinated relation, to cause the composite stock to move in unison tothe stock take-up means, such as a creel or a rectilinear extended chaincarrier where continuous lengths of from fifty to one hundred feet arecollected in the flat, preparatory to packaging in short lengths or incoils to provide a closely wound coil of about 24 inches in diameter, asdescribed, for a one hundred foot length.

By my invention, substantial economies are effected in packaging,storage, handling, labor and working conditions, while producing abetter quality product then described in my prior application. While Ihave exemplified one form of my invention, it will be understood thatmodification will now readily become apparent and that the scope of myinvention is to be broadly construed.

Having thus described my invention and illustrated its use, what I claimas new and desire to secure by Letters Patent is:

1. A feeder for apparatus for simultaneously and continuously attachingmetal strips to a Web of fabric at its opposite margins by successivepairs of folding rolls successively to bend the metal strips and fabricinto engagement, the combination having means to direct the metal stripsin spaced position at a predetermined width and in overlapping contact,comprising bed means having lateral guides and aligning rolls for urgingsaid strips into contact, with said lateral guides engaging the outeredges of said strips.

2. A feeder in accordance with claim 1 wherein said aligning rollscomprise axial mounting having toe-in camber to press the side edges ofsaid metal strips, during rolling, into contact with said lateralguides.

' 3. A feeder for apparatus for simultaneously and continuously.attaching'a metal strip to opposite margins of a web of fabric bysuccessive pairs of folding rolls successively to bend said metal stripsand fabric into engagement, the combination having means initially todirect the strips in spaced position at a predetermined Width and inoverlapping contact to said folding rolls comprising bed means havinglateral guides to limit the position of the outer edges of said stripsand rolls constituting the sole means contacting said strips adjacentthe outer edges to hold said strips with their outer edges in engagementwith the lateral guides in the movement of the strips to said rolls.

4. In a feeder for apparatus for simultaneously and continuouslyattaching metal strips to a web of fabric at its opposite margins bysuccessive pairs of folding rolls successively to bend the metal stripsand fabric into engagement, and feeding the same into multi-layeredpackages of coiled stock, the combination having metering rolls of pairsof mating rolls, opposed members of mating rolls on the same face beingcoupled to rotate in unison and being of differential peripheraldimension, to secure a controlled coil feed of each strip in relation tothe other, whereby a substantially unwarped coil package of said stockis provided.

5. In a feeder for apparauts for simultaneously and continuouslyattaching metal strips to a web of fabric at its opposite margins bysuccessive pairs of folding rolls successively to bend the metal stripsand fabric into engagement and feed the same into multi-layered packagesof flat stock, the combination having metering rolls of pairs of'matingrolls, opposed members of the mating rolls on the same face beingcoupled to rotate, in unison and being of the same peripheral dimensionto secure a con trolled flat feed of each strip in relation to theother, whereby a substantially unwarped flat package of said stock isprovided.

References Cited by the Examiner UNITED STATES PATENTS 2,749,961 6/56Czarnik 153-1 2,778,100 1/57 Lipman 29-509 2,852,842 9/58 SkOW 295093,017,694 1/62 Goldsmith l53-l 3,060,991 10/62 Chausson 153--l CHARLESW. LANHAM, Primary Examiner. WHITMORE A. WILTZ, Examiner.

1. A FEEDER FOR APPARATUS FOR SIMULTANEOUSLY AND CONTINUOUSLY ATTACHING METAL STRIPS TO A WEB OF FABRIC AT ITS OPPOSITE MARGINS BY SUCCESSIVE PAIRS OF FOLDING ROLLS SUCCESSIVELY TO BEND THE METAL STRIPS AND FABRIC INTO ENGAGEMENT, THE COMBINATION HAVING MEANS TO DIRECT THE METAL STRIPS IN SPACED POSITION AT A PREDETERMINED WIDTH AND IN OVERLAPPING CONTACT, COMPRISING BED MEANS HAVING LATERAL GUIDES AND ALIGNING ROLLS FOR URGING SAID STRIPS INTO CONTACT, WITH SAID LATERAL GUIDES ENGAGING THE OUTER EDGES OF SAID STRIPS. 